Method and apparatus for vertical torch oscillation inversely to current magnitude

ABSTRACT

A process and system for welding of the tungsten inert gas (TIG) type is described. A welding torch is mounted on a mechanism which provides for motion of the torch with respect to the work (a pipe being welded) in three different directions. Movement in each direction is electronically controlled so as to obtain preset magnitudes of oscillation of the torch, both vertically and laterally with respect to the work. The vertical oscillation is provided by following the pulsating arc current in accordance with a preselected control function. In addition, the system and process provides for control of substantially all of the parameters affecting the formation of the weld in order to produce improved weldments.

Poem

UniiteStates Patent fll 'fiCenieron et al.

154l- METHOD AND APPARATUS FOR 7 VERTICAL TORCH OSCELLATION INVERSELY TO CURRENT v MAGNITUDE M lmientors: James A. Cameron; Niantic; Joseph Lanuiame; Gales Ferry. both of Come;

Leonard E Mann, Woodridge, lll. I l As'signecr General Dynamics Corporation, v New 3" 'York,N.Y. f 1111;] rgieai" I Oct. zsi, 1 968 :Ap mo; 304,332

3.81325 3.l82,l78 /1965 Lib 3,230,341 [/1966 Blackburn 1 3,428,774 2/i969 Faust et al ..2l9l137 X g 2 1"*o.s.ci..-.; n; ..'....Q ..Zt9/.l37,219/l3l.219/124 v.

[ Feb. 29,1972

44/1964 Briggs ..2l9ll3lFX Primtzry Examiner-J. V.Truhe Assistant Examiner-George A. Montanye Attorney-William C. Everett {57] ABSTRACT respect to the work (a pipe being welded) in three difi'erent directions. Movement in each direction is electronicdly controlled so as to obtain preset magnitudes of oscillation of the Int.(l 823k 9/00 I V i torch, both vertically and laterally with respect to the work. K 9 Ti 2 A The vertical oscillation is provided by following the pulsating I are current in accordance with a preselected control function. a g Rrferencescmdr in addition, the system and process provides for control of 5 f I? NI ST S PATENTS substantially all of the parameters affecting the formation of 1 1 .i the weld in order to produce improved weldmems. j 2.8l3,'l90l1li957 Felmley, Jr..-..; .2l9/76 1 $053,975 9/1962 Nelson et al ..2l9/ v 4 Claims, 20 Drawing Figures warm 4.4/0 ses F CONTROL srsreu l l 3o 22, j J 24 a l8;

- CUFEJNT colvm a'z uwc TROL srsrflf "$51!? 575750! sup/{y Q VERTICAL J 05C/L.' .47'/0N 1 CONTROL /5 s'rsrau HEIGHT, U 28 LAVERAL HRH/E l DRIVE cowrpo J r srsr, L ,MREFEED WIRE FEED saw 011;;

- WATER AND GAS I CONTROL srsrsm POWER I SYSTEM SUPPLY comma 1 1 1' SYSTEM HEIGHT,

28 LATERAL; DRIV DRIVE CONTROL F MECHAN- srsrs/y V W/R FFFD mu v 4 2L 34L f 3 CLOCK COUNTER B60 DEC/MAL CONVERTERS MEL? 4 T Y 4 J i 441 7 I MANUAL SELECT/0N fi/A/VUAL SELECT/0N MANUAL SELECT/0N SW/TCHES SW/TCHES I SW/TCHES i I 46- 4a 50 A/VD AND 5 2 L 34 v 56 FF FF L 1 FF 7 JAMESM. CAMERON JOSEPH LA/VZAFAME LEONARD 5. MA lV/V IN VENTORS CLEAR [MBLE SLOPE AL OSCILLA T/O/V, {Rm/5 CURRENT "IE/r flhwrney Emmi *EA/A BLE ,WFP

PATENIEBnnzsWz I SHEET 070? 10 JAMES M. CAMERON JOSEPH LA/VZAFAME LEONARD 5. MAN/J INVENTORS [hair a/Iom ey Hawk? f" PATEmEmabe1972 SHEET 10m 10 JAMES M. ammo JOSEPH LA/VZA FAME LEONARD E. MAN/V INVE/VTO/RS' I/le/r affomey In the practice of f cur-lent is applied to order to control both the melting and solidification of the weld. The control of the waveform of the current pulses prof vides a measure ofcontrol of resulting weld. it has been found,

' however, that additional control is desirable in order to ac- METHOD AND APPARATUS FGR VERlICAL TORCH I OSCILLATlON INVERSELY TO CURRENT MAGXITUDE The presentinvention relates to methods and systems for Y arc welding, and particularly .to systems and process for are 3 welding wherein a pulse current is supplied to form the arc.

The invention is especially'suitablc for use in pulsed are welding systems of the nonconsumable electrode type which 1 are also known as tungsten inert gas or TlG welding systems. While the invention is described in connectionwith the welding of joints between sections or" pipe, it will be appreciated j that features of the invention provide .trol of substantially all parameters afiecting the formation of a for the automatic conweld and therefore the invention may be applied to accomplish welding regardless of the type of weldment. joint design, positional relationship of torch with respect to the work or the metallurgical characteristics of the materials to be welded.

pulsed arc welding, a pulsating welding we torch'during the welding cycle in complish fully automatic arc welding of the joint which may be encountered. Automatic arc welders which are available have been limited to applications where the work remains essentially in the same position with respect to the weld. While control over the pulsed arc permits greater flexibility in weld torch positions, more flexibility is required in order toprovide for universal automatic arc welding. lt has been found in I 'ditional parameters which affect the weld may be provided and controlled in a manner integrated with the control of the pulse are so as to provide a practical fully automatic arc weld- 1 ing machine. A welding machine embodying the invention therefore is adapted to produce precision wcldsand to operate in all positions, thus making automa ic welding possible where only slow manual welding techniques could heretofore be used. The parameters-which have been made amila'ole for control in accordance with the invention are an oscillatory movement of the torch with respect to the work, both in a vertical direction (viz height control) and in a transverse direction (viz laterally across the weld). 'lhe cxillan'ons may be synchronized with the current pulses supplied to the arc in order to provide integrated control of the formation of the weld (viz to control melting and fusion).

Thus, it is a feature of the invention to provide controllable parameters which are effective in determining the nature of a weld and to integrate the control of such parameters so as to make the welds rapidly, precisely and inespective of the posi tion of the weld with respect to thev torch. Among the parameters referred to above are current magnitude, current pulse, shape and rate, oscillatory movement of the torch with respect to the work, both vertically and laterally, and longitudinal movement of the work with respect to the torch (viz travel of the torch along the weld).

Further features of the invention are to provide protection both of the work and the torch in the event of failures in the i system such as loss of inert gas, cooling water, breakdown of electrical components and the like. a Still further features of the invention reside in the ease wi which the system may be setup and adjusted to accommodate various sizes of work.

Another feature which is afforded by the availability of control over all of the welding parameters is that it facilitates the use of lower arc voltages. thereby reducing the possibility of burning and other damage to he work.

Still another feature arcing out cf the availability of the 7 controlled weldingparameters is precise quantized agitation of the weld puddle so as to control the metallurgical characteristics of the weld. The control over the weld parameters also provides control of the contour of the weld and substantially eliminates undercutting of the sidewalls of the welded joint.

The principal object of the invention therefore is to provide an improved process of and system for pulsed arc welding which is capable of producing weldments automatically.

. still further object of the invention is to provide an improved process of and system for pulsed arc welding which controls parameters which are effective in determining the nature of a weld so as to produce better welds faster than heretofore feasible.

itiated automatically and in a manner which will prevent damage to the torch as well as to the work. in earlier auto- V i designs, materials, and work to torch positional relationships matic arc welding machines, arcs were started by applying high-frequencyenergy in the region between the torch electrode and the work. The highpower high-frequency generator necessary to supply the starting energy is both costly and provides undesirable side effects, such as interference with radio transmission and reception.

it has been found in accordance with this invention that such high-frequency techniques may be eliminated and the are initiated by automatic means for applying the starting current to the torch in timed relationship with the movement of the torch from a position in contact with the work to a position away from the work.

Accordingly, it is an object of the invention to provide an arcv welding system having simplified means for initiating the are which prevents any damage, either to the torch or to the work during arc initiation.

Briefly described, a method of and system for pulsed are 7 welding embodying the invention includes the step of applying ing arc current, thereby providing another parameter effective in determining the nature of the weld. This parameter may be controlled by sensing the pulsating arc voltage and generating a control signal in response thereto which is adapted to move the welding torch in a direction and with an amplitude to provide the desired control over this vertical oscillation parameter. The welding torch may also be oscillated laterally with respect to the weld to provide another parameter which may be preset, both as regards the amplitude and location of the lateral oscillatory movement of the torch with respect to the weld. The movement or trave. of the torch with respect to the work lengthwise along the weld is also controlled so that the arc is initiated and all of the other parameters affecting the weld are established and are maintained in proper time relationship over successive regions of the weld.

Mechanisms are provided for positioning and oscillating the torch as well as for moving the entire torch assemblage with respect to the work so as to travel along the weld. These mechanisms include means for adjustment to accommodate various sizes of work in a manner not to interfere with the oscillation of the torch, both vertically and laterally with respect to the weld.

The system for initiating the arc utilizes the means for vertically oscillating the torch to touch the work and further includes circuits for detecting the starting current and moving the torch away from the work. A control circuit is also provided for electrically preventing the torch from leaving the work until the current supplied to the torch is within the range which will start the are without causing damage to the work.

The invention itself, both as to its organ cazon and method of operation, as well as additional objects and advantages thereof will become more readily apparent from a reading of the following description in connection with the accompanying drawings in which:

circuits which control the initiation of the arc; g FIG. 7 is a block diagram of the vertical oscillation control m. 1" is a block diagram of a welding system embodying the invention;

FIG. 2 is a'rnore detailed block diagram of the programming 7 system shown in FIG. I; a

FIG. 3 is a more detailed block diagram of the current con- I trol system shown in FIG. I;

FIG. 4 is ablock diagram showing a portion of the drive control system shown in FIG. 1;

FIG. 5 is a block diagram of the welding power supply system showing means for generating the welding current and protecting the torch and work, both during arc initiation and weldingoperations; 1 I

FIG. 6 is a schematic diagram, partially in block form. of the system schematically showing the circuit for controlling the vertical oscillation drive motor,

HO. 8 is a block diagram of a portion of another system for and arc length which is obtained by means of the system shown in FIGS. 7-9;

v 4 operative to provide an enabling level to logic circuits in a vertical oscillation control system 26 which is coupled to the section of the drive mechanism 16 which enables vertical oscillation of the torch 10 with respect to the work. and therefore controls the height of the torch over the work 12.

After the height control command is provided by the programming system 22 to the vertical oscillation control system 26, the circuits therein which control the movement of the torch towards and away from the work upon starting or arc initiation are activated. After the arc is initiated. other portions of the vertical oscillation control system 26 are operative to sense the pulsating current which is supplied to the torch by the welding power supply 18 under the control of the current control system 24, whereby to oscillate the torch vertically during the welding cycle in synchronism with the current pulses. Digital timing circuits in the timingprogramming system 22 also enable the drive control systems 28 which control the lateral oscillation drive in the drive mechanism i6. as well as the travel and wire feed drives of the rncchanisn 16. Upon receiptof these command signals, the drive control system 28 is then enabled to provide the preselected rates of lateral oscil- FIG. 11 is a graph showing the variation of arc current and 25 arc length with time;

FIG. I2 are waveforms illustrating the interrelation of variation of arc voltage, arc length, and arc current with time;

FIG. 13 is an elevational view of the mechanism of the auto matic arc welder which embodies the invention;

FIG. 14 is the top view of the mechanism shown in FIG. 13;

i FIG. 15 is a view similar to FIG. 13, but showing the filler wire feed mechanism in greater detail;

FIG. I6 is a plan view, partially in section, of a. portion of the mechanism shown in FIG. 13 which illustrates the lateral oscillator drive mechanism in detail;

FIG. 17 is a fragmentary sectional view similar to FIG. 16, but showing a portion of the mechanism depicted therein in greater detail:

FiG. i8 is an elevational view, partially in section of the lateral oscillator mechanism shown in FIG. 16, but in adifferent position from that shown in FIG. 16;

FIG. 19 is a sectional view taken along the line 19-19 in FIG. 18; and

FIG. 20 is a perspective view of one of the work supports a which is shown in FIG. 13.

Referring more particularly to H6. 1, the arc welding torch I 10 and the work 12 to be welded at a joint 14 are schemati- 'cally depicted. The work 12 may be sections of pipe, as shown in FIG. 13. FIG. i345) aiso illmt ate the mechanisms 16 which support and drive the torch l0 and the work 12 so as to accomplish welding automatically. The electrical energy for providing the arc which causes melting in the joint region and of any-filler material supplied thereto is provided by a welding power supply 18, the output terminals of which are connected respectively to the work l2 and to the electrode in the torch 10. The torch 10 also receives inert gas and cooling water from a water and gas control system 20. This system contains valving, as well as detectors for monitoring the flow of water and inert gas.

The driving mechanism 16. the welding power supply 18 I and the water and'gas ccntrcl system 20 are all controlled so as to make the we!& automatically. Automatic control is obtained by means of a timing and programming system 22 to be I described in greater detail in connection with FIG. 2. When the welding cycle is initiated, say b pressing a start button, a command level is applied to the electrically controlled water and gas valves in the water and gas control system 20. After an 3 appropriate delay, as is obtained by digital delay devices in the programming system 22, a command is provided via a current control syst m 24 to the welding power supply which energizes the electromagnetically operated switches which conace! the powerlines to the welding power supply 18. Digitally trol system to decrease the welding current (hereinafter referred to as a slope enable command). This command is also used in the timing and programming system 22 to generate commands for the drive controi system 28 to stop the lateral oscillations and wire feed, as well as to control the vertical oscillation control system 26 to stop the height changes of the torch, thus keeping the arc length constant An output 30 which is obtained from the current control system circuits, which produce the decreasing welding current, is detected in the timing and programming system 22. When this output reaches a predetermined level, indicative of reduction of welding current to a level which will permit cutcfi'ofsuch current without difficulty due to transients and the like, the timing system initiates a clear command which stops all of the drives, shuts down the welding power supply, as well as the supply of water and gas. The gas and water may be permitted j operative timing circuits the programming system 22 are to flow during a short post flow time after shctdcwr by virtue of a delay circuit which is switched into the water and gas flow control system 20 upon initiation of the clear command.

FIG. 2 is a simplified block diagram of the timing prograrnming system 2? The primary timing signals are obtained from a clock source 32 which may be the 60 Hz. alternating current line. The clock source 32 may include shaping circuits which provide pulses at the 60 Hz. rate. These pulses are applied to a counter 3 in which the pulse rate is divided by six to provide pulses at a 10 Hz. rate. The 10 Hz. pulses are then applied to a chain of BCD counters 36. The outputs of the counters are converted from binary coded decimal to decimal form in binary coded decimal (BCD) to decimal converters 38, one of which may be provided for each of the BCD counters. The conversion therefore produces a plurality of groups of outputs (five being shown in the drawings) from the BCD to decimal converters 38. The first group contains ten outputs, each corresponding to one-tenth second intervals. In other words, a puise will occur on each of the outputs every one-tenth second, two-tenth second to nine-tenth second. The next group of outputs will provide pulses which occur at one second intervals. Only one output is needed for pulses which occur every I ,000 seconds.

Manually controllable switches (M88) 40, 42 and 44 are used to select groups of combinations of outputs from the BC!) to decimal converters 38. The selected outputs are applied to AND-gates 46, 48 and 50 to produce timing signals which occur at selected intervals. the output of the AND-gate 46 connected to the first M88 40 will be a pulse occurring at puts of the AND-gates 48 and 50 which are connected to the M55 land 44 may be a pulse occurring at any one-tenth second interval from one-tenth second to 1999.9 seconds. I "These pulses are applied to and stored in flip-ilops 52, 54 and 56. When the flip-flop 52 is set, an enable travel command is applied to drive control system 28 (H6. 1) so as to start the motor which drives the work 12. Similarly, after the time delay selected by the M85 42, the flip-flop 54 will be set and will apply an enablecommand to the current control system 24 which will cause the system to apply a control signal to the welding power supply 18 so as to change the magnitude of the. welding current. This change in welding current mgnitude is referred to herein as a ?current step." At the end of the weld ing cycle as preset by the M88 44, the flip-flop 56 will be set and enablea slope command. This slope command is applied to the currentcontrol system and causes the welding currents 65, 68 and 0. depending upon the absence or presence of a high-level or low-level pulse signal and the absence and to'be decreased gradually until the arc is extinguished. The i enable slope command is also applied to a NAND-gate 58,

together with the output of the Tip-flop 52 which is complementary to the output which produces the enable travel command. The NAND-gate 58 output is inverted in an inverter 60. By virtue of the logical function of the NAND gate and the inversion .ofits output, the enable height lateral oscillation and wire feed command will he produced only when the flip-flop 52 is set and the enable slope command is not present. The presence of the enable-slopecommand inhibits the enable height, lateral oscillator and wire feed commands, thereby p esence of the enable current step command. in the absence of the enable current step command, the selection logic network 64 applies low-lcvel pulses to the MC? 70 and the highievel pulses to the MC? 68. The presence'of the enable cur rent step command and the high-level pulse signal provides an output to the MC? 66. In other words, the selection logic performs an exclusive OR operation in selecting the MCPs 68 or 76 which independently vary or set the amplitudes of the level portions of each pulse cycle. The output of the MC? 68 is therefore labeled high set, while the output of the MC? 76 v is labeled "low set. The output of the MC? 66 is labeled hign step since it provides an indemndent current level which may be higher or lower than the selected high set level. The acswitch is operated to allow time for gas and water flow to be stopping the wire feed and lateral and vertical oscillation of i the torch and moving it away from the worlt.,This is accomplished by means of logic circuits in the welding power supply .and vertical oscillator control system to be described in connection with FIGS. 5 and 6. A slope level detector (not shown) in the current control system 24 generates a clear pulse when the control current generated in response to a slope command decreases to the level requisite for system shutdown. This pulse resets the flip-flops 52, 54, 56 and the counters 34, 36.

Lather outputs (not shown) may be taken from the BCD to decimal converters 38 via additional manual selection switches (also not shown) to control other functions in the au tomatic welder, such as the duration of the starting current which is produced by the current control system 24, and gas preflow and postflow before and after the welding cycle; the latter being obtained by commands applied to the water and gas control system 20 (FIGL l The current control system 24 is schematically depicted in the simplified block diagram of HO. 3. The purpose of the current control system is to generate a control voltage for the welding power supply 18. During normal welding operation, this control voltage is in the form of pulses rich are generated by a pulse generator 62 which may be controlled to produce the pulses with different selected rates and durations. A typical pulse rate may be of the order of 2% Hz A typical pulse duration may be 300 milliseconds during which the pulse is on or ofhigh level, and 300 milliseconds during which the pulse is off or of low level. The pulse generator 62 itself may comprise a pair of one-shot multivibrators, each of which has an adjustable time constant so as to select the pulse dura- 1 tions and rate. The one-shot multivibrators are connected in a loop circuit so as to be free running. In the even that a constant high-level or low-level control voltage is desired to be supplied to the welding power supply so as to obtain a constant current are, rather than a pulsed arc, a control circuit may be associated with the pulse generator to inhibit free 7 running of the pulse generator and to condition the generator output to remain either at high or at low level.

The generator output signal is applied to the current amvplitude selection logic network 64 consisting of a suitable combination of digital gates. Also applied to th s logic network 64 is the enable current step command from the flip-flop 54 in Y the timing programming system 22 (H6. 2). The current amplitude selection logic network provides outputs selectively to three different manually controllable potentiometers (MC?) established.

The output of the last-mentioned amplifier. together with the outputs of the MCPs 66, 68 and 70 are applied to a summing network 72, which may be a resistor matrix, in order to develop the current control signal. This control signal is applied to a DC amplifier 74 and supplied as a control voltage to the welding power supply.

The summing network 72 also receives an input signal from a slope amplifier 76. The slope amplifier is an integrating amplifier and generates a slope signal by charging the capacitor in its feedback circuit. or charging circuit 78. An MC? is connected to the charging circuit 78 so as to control the charge time constant and therefore rate of change of the slope voltage which is produced by the slope amplifier 76. A trigger circuit 82. such as an FET (field-effect transistor) gate is turned oil to allow the charging circuit 78 to charge upon the mipt of a slope initiate command. the flow detection and sa ety circuits can also command a slope.

it will be recalled that the slope initiate command is provided at the end of a normal welding cycle. Slope control voltages may, however, be generated under other circumstances. For example, in the even that there is a failure in the gas or water supply system 20 FIG. 1), detector circuits in that system provide outputs which operate a safety trigger circuit 86. This circuit will also cause a slope initiate command and may include additional resistors so as to insure the necessary rate of change (slope-out) of the welding current.

The drive control system 28. (FIG. I) may include a motor control system, such as shown in FIG. 4 for the travel motor which drives the work, as well as for the wire feed and lateral oscillation drive motors. Each of these drive systems includes a DC servomotor, such as the motor 90, shown in H6. 4. A tachometer 92, which is coupled to the shaft of the motor, provides a feedback signal to a servoamplifier 94 which may be a direct current amplifier which provides an amplitudecontrolled DC drive signal to the motor 9%. The amplitude of this drive signal from the output of the servoamplifier is con- Zled by an MC? 96. A run command which is associated with the motor is applied to the input of the MC P 96. Thus, when the run command is not present, the servoamplifier will produce no operating current for the motor 90 and the motor 90 will stop. The presence of a run command therefore enabias the operation of the drive mechanism and the absence of the command inhibits such operation.

The welding power supply 18 is shown in H6. 5. It includes a three-phase alteranting current supply provided by a three-phase transformer which is connected to the line via the electromagnetically operated actuators which pull in when the start button is pressed and dropout at the end of the welding cyclc..as was explained in connection with H6. 1. The AC supply 100 feeds a three phase magnetic amplifier 102 having bias, control and output windingsDC bias for the bias winding is obtained from a bias supply rectifier circuit 104 coupledv to the AC supply. Terminals are connected to opposite ends of the control windings. The output windings are connected through current transformers 112 to rectifiers 110 which provide the welding current across negatively and positively polarized output terminals. The negative terminal is connected to the torch electrode. while the positive terminal is connected, after passing through the primary winding of a rate v, I feedback transformer 11!, to the work which is desirably grounded.

Current feedback is obtained from current transformers 112 which are inductively coupled to each of the three phase lines from the magnetic amplifier I02 to the rectifiers 210.

The currenttmnsformers outputs are rectified in diode bridge rectifying circuits for example, which constitutes the rectifier 114. The. rectified output voltage is passed through a low-pass filter M6 to remove the ripple component thereof, and is applied through a summing circuit 118 which may be a resistive matrix, together with the control voltage from the output am plifier 74 of the current control system (H6. 3). The DC current feedback from the rectifiers 11-5 is opposite in polarity to i i I, the control voltage so as to stabilize the welding current which is produced to the current which is preset or ordered by the control voltage. The output of the summing circuit is connected to a'DC amplifier 120. The output of the amplifier is connected across the magnetic amplifier control winding in V series with the secondary of the rate feedback transformer 111 which applies a predetermined level of the ripple voltage in opposite phase to effect the cancellation thereof. it also is fed to a monitor 12 which determines if it is within a predetermined acceptable range. A current OK signal is the output.

lnasmuch as the control voltage will normally be a pulse train, the welding current will consequently also normally be j in the form of pulses. The DC amplitude of the current, however, may readily be detected by a weld current amplitude de- 7 tector IZZJThis detector 122 provides separate outputs to a protective switch circuit which provides a short circuit as occurs when the welding current exceeds the 6 amperes level, the resistance presented by the light dependent resistor 138 is highand effectively presents an open circuit. The slight voltage drop across the resistor 14! is too low to permit the capacitor 134 to charge to a level sufficient to generatca trig I flows through theDiac, experiencing a small voltage drop I therein, and thence through a diode 248 and the primary of a transformer 150. The pulse which is generated upcn break down of the Diac is translated through the transformer 150 to the trigger electrode of the main SCR 130, causing it to oreak down. Thus,.a short circuit is established. The capacitor 13.:

between the torch electrode and the work during starting of the arc in order to protect both the electrode and the work. The other output from the amplitude detector is applied to a threshold circuit 126 which enables the height control (viz the vertical oscillation of the torch) when the welding current is greater than a predetermined magnitude, say 27 amperes.

The protective switch circuit 124, the amplitude detector I22 and the threshold circuit 126 are shown in detail in FIG. 6.

The starting protective switch circuit 124 prevents current 7 flow from the torch eiectrodes to the work until the current transient disappears and conditions are right to form an arc.

This circuit, as shown in detail in FIG. 6, contains a main silicon control rectifier (SCR) 130 which is connected in series with a fuse across the welding current supply line 132 from the rectifier to the torch electrode. When the welding supply is turned on, the voltage between the line and ground is substantially'full magnitude, typically 80 volts. The voltage charges a pair of capacitors 134 and 136. The capacitor'134 has a resistor 141 connected thereacross in order to prevent retriggering of the SCRs in the circuit 124. as will be explained more fully hereinafter; These capacitors 134 and 136 are permitted to charge only during starting by reason of the light dependent resistor 138 which is connected in their charging current cannot discharge through the circuit containing the Diac 146. diode M8 and transformer 150 in view of the polarization of a diode 152 which is in series with the capacitor 136 in this circuit.

When the current to the short circuit (SCR 130) reaches 6 amperes, approximately, the signal from the current transformer rectifier 1M (FIG. 5) exceeds the threshold set in the amplifier 142. Thus, the lamp 140 is extinguished and the resistance of the light dependent resistor 138 increases to its open circuit value. The weld current amplitude detector 122 is operative to cause the breakdown of a pair of secondary SC Rs 154 and E56, thereby providing a discharge path for the capacitor 136. This discharge path is completed through the conductive primary SCR 130. However, the current flow from the capacitor 136 is in a direction opposite to the current flow between the line 132 and ground. in other words. a bucking \oltage to the voltage to which the capacitor 136 is charged opposes the voltage tending to sustain the breakdown of the primary SCR 130. The SCR 130 is thereupon cut off removing the short circuit between the torch electrode and the "work. Upon the discharge of the capacitor 136, voltage which sustains the conduction through the secondary SCRs 154 and 156 is also no longer present, thereby causing these SCR: to become nonconductive.

After a predetermined preflow time, and if the current and voltage of the welding power supply output are normal the height control is energized and the torch drives to touch the work. The current now begins to flow through a saturable transformer 158.

The weld current amplitude detector 122 contains saturable transformer 158 which controls the current flowing around a circuit including the secondary of a transformer 160 and a resistor 162. The transformer 160 is connected across the alternating current supply line. Therefore, as the saturable transpaths. This resistor is illuminated by a lamp 140 only at such time as the current being supplied by the welding power supply is low, say below 6 amperes. This current is detected by means of a threshold amplifier 142 which is connected to the rectifiers 114 in the welding power supply (see FIG. 5). So

v long as the threshold is riot exceeded, a transistor 144 is operated to its conductive state. When the lamp 140 goes off,

former 158 becomes partially saturated due to the torch touching the work, the voltage drop thereacross decrea es the voltage appearing across the resistor 162 increases. The voltage across the resistor 162 is rectified by a half wave rectifier circuit including a diode 164 and a capacitor 166. A resistor 168 completes the rectifier circuit. The voltage developed across the capacitor F66 in the rectifier circuit is sufficient to break down a Diac 170 when it reaches a value corresponding to a current flow through the line 132, equal to approximately 6 amperes. Breakdown of the Diac sends a current pulse through the primary of a transformer 172, the secondary windings of which are connected to the trigger electrodes of the secondary SCRs 154 and 156. Thus, these SCRs then fire to remove the short circuit.

The weld current amplitude detector also includes another half wave rectifier circuit 174 which is connected across the resistor 162. The voltage developed across this amplitude detector appears across a potentiometer 176 which is part of the threshold circuit 125. The threshold circuit itself includes a zener diode 178 which is connected through a coupling resistor 180 to the base of a transistor 182. When the threshold is exceeded, the zener diode 178 conducts, causing the transistor X82 becomes conductive may be adjusted so that the proper starting current (e.g., 27 amperes) is at that time flowing through the torch. The threshold circuit 126 also actually measures the current to the torch by virtue of being conl nected to the weld current amplitude detector 1122. Thus,

there is reasonable assurance that the proper welding current l is flowing through the torch at the instant when starting is desired. Starting, as well as vertical oscillation, is under the control of the programming system and cannot occur until the enable height command from the inverter 60 (H6. 2).'Flip flop 186 can be toggled if the .l input is high. The J input is high if the torch current is within normal limits. This is to prevent possibly burning a. hole if the current is very high, as"

the torch lifts from the work. if the current in the torch is normal, a ground excites lamp dependent resistor therein to its minimum value. This low resistance .now makes the .l input high. The necessary voltage levels are determined by the voltage division accomplished b resistor 190 and the light dependent resistor in cell 188. The clear input to the flip-flop is low to clear the flip-flop and high 7 to enable. When the electromechanical actuator is actuated,

the level to the fiipflop 186 is high. When the actuator is deenergized the level is low.

The vertical oscillation control system is illustrated in greater detail in FIG. 7. it includes a source of direct current operating voltage indicated as being a DC supply 200. The amplitude of the oscillation is controllable by adjusting the positive value of the voltage which is applied. to a summing circuit 202 which may be a resistor matrix. This control over this voltage is obtained by a manually controllable potentiometer 204 which may have separate sections so as to vary this voltage in coarse and fine steps. The voltage between the torch and the work iz'the arc voltage) is sensed by anarc voltage sensing circuit 206. The polarity of this voltage is opposite to 40 the polarity of the voltage applied from the supply to the summing circuit 202 via the MC? 204. Overdrive circuits 208 and 210 which provide voltages of opposite polarity to drive the torch, respectively, out or away from the work. and in or toward the work are also provided, principally for starting purposes. Another circuit is provided indicated as being a corona delay circuit 212. This circuit applies an overriding voltage to the summing circuit during the short time interval immediately after a voltage drop appears between the torch and the 21 188, thus changing in: light 2 FIG. 10 illustrates the variation of height with are cur which occurs when the arc voltage is maintained constan .is accomplished by means of the servosystem shown in FlC As the arc current increams, the arc \oltage tends to fol this increase. Thus the variation in the height of the torcl reason of the control system shown in FIG. 7 tends to decre the height (viz the height is an inverse function of the r I rent). This relationship is shown in H6. It. The pulsating current which is produced by the current control sysl therefore tends to produce with a slight delay a pulsating voltage, as shovm in HQ :2. The oscillations in the lzeighl the torch with respect to the work follow this are voltage shown in FIG. l2. A uniform oscillation therefore is produc by reason of the vertical oscillation control mechanism a circuits because the current control system produces cum ulses which force such oscillation. Without such current i ses, oscillation would not be produced. Such oscillation is important parameter in controlling the formation of the we The system provided by the invention and the method of t invention is to produce such oscillations and then contr them to obtain the desired weld characteristics.

' In the altemative embodiment of the vertical oscillator co trol system. shown in FIG. 8, the output of the summing circt 202 is amplified in an amplifier 234 which is similar to the ar plificr 214. The output of this amplifier 234 is divided into N channels, one of which contains a single amplifier stage 23* while the other contains a pair of stages 238 and 240 cor nected in tandem. Thus. the output of the amplifier 236 will l:

180 out of phase with resto the output of the an'lplilic v 240. These signa s are appl'gd as gating signals to pulse tran:

formers :42 and 244. Tne plse transformers gate signals fror an oscillator 246 whic provides a constant frequency outpu signal, which is desirably in the range of 600 Hz. to 2 kllz. It the motor control system. This motor control system may con tain Tn'acs, such as the Triacs 218 and 222 which an separately triggered by the outputs of the pulse transformers depending upon which of the transformers receives a contro signal of proper polarity to enable the transmission of the oscillation therethrough. The distance which the torch move: away and then towards the work depends, of course. upon the transformers 242 and 244. inasmuch as the frequency of the o "i lator 246 is relatively high. the movement of the torch in 45 any directirn occupies a number of cycles of the oscillator work, until the effective corona resulting from that drop have self is connected between the terminals 262 and 2.64, with the time to dissipate. The output of the summing circuit controls a DC scrvoamplifier 214.

sense in accordance with the direction in which it is desired to move 'he torch. When the voltage is 0, no torch movement is, of co rrse, desired. When the voltage increases in one sense, say positive, it is applied to a diode 216 to trigger a solid state switch 218 of the type known as a Triac." Triac is a tradeelectrode of the torch (which is maintained at a negative potential) connected to the terminal 262, while the work or ground terminal corresponds to the terminal 264.

The resistor 266 and capacitor 268 connected between the torch and its summing resistor 250 provide filtering of the powerline frequency component which appear at the torch elemrode. A. resistor-capacitor network 270 is connected across Lhe output of the rectifiers I14 and provides the adjustable signal to the summing point 260. this adjustable signal mark of the General Electric Company for such solid state may be varied from zero toa maximum level by potentiometer switches. Similarly, if the error voltage amplified y the DC amplifier 214 is of the opposite or negative polarity, current corresponding thereto passes through an oppositely polarized diode 220 and triggers another Triac 222. The Triacs switch the alternating current flow from a transformer 224', which is current, i.e., when the current increases the arc length inconnected across he alternating current line, through either of the split phase windings 226 and 228 of the servomotor 230. The shaft of the motor therefore may turn in opposite directions, causing. the vertical oscillation drive mechanism which is coupled thereto to oscillate. This oscillation is princonditioned to provide t 274. With potentiometer 274 at zero, the vertical oscillation is maxim n and inversely proportional to are current. conversely, with potentiometer 274 at a maximum the vertical oscillation is maximum, but the motion is now in phase with the arc creases. Another feature of this control is that when potentiometer 274 is at its center position, the vertical oscillation can be completely cancelled, and pure arc voltage control is obtained.

The voltage appearing across the torch terminals 262 and 264 is amplified in at threshold amplifier 278 which provides an output for enabling an AND-gate 280 when the arc voltage is above a certain level indicating that an arc can be maintained or is already present. The AND gate, houzver, is not he desired logical output level, unless g .3,646,3l.l

I it a 12 s and until aweld current presentcomrnand (viz. 6 ampercs pivotable away from each other about a pivot pin 310. The 1 v welding current) is obtained. from the lip-flop 186 (FIG. 6) junction 312 of the sections 306 and308 which come together which is triggered when the current control voltage and when the carriage is clamped on the pipe 300 is provided with y proper welding current amplitude is present and the prolatches 313 and a clamp 315 which hold the sections 306 and gramrning system has also provided a command to enable 308 in clamped relation on the pipe.

height control. With the logical command present. at the input The feet 304. as shown in H0. 20. is made up of a stanchion ito the AND-gate 28$,an output is provided which inhibits a' 314 which is screwed into the carriage 302. The upper portion I; lamp driving amplifier 282 which provides enabling current to of the stanchion has a slot 316 therein in which a flat spring f 5a lamp L2 linked toa light dependentresistor 1.,DR which is 318 is secured by means of a screw 320. The spring 318 is connected betweenasource of negative potential indicated as 10 mounted on a block spacer to provide clearance. A pair of g B and the summing matrix resistor :56. Accordingly, the buttons 322 actually engage the pipe. When the carriage sec- "lamp L2, is normally illuminated. thereby 1 ""ering the re tions 306 and 308 are closed. the spring plates locate them- 'sistance of the resistor LgDR so that a negrim potentia may selves into the slots'3l6 and the proper amount of tension is be applied to the summing point 260. This or. 2': potential 5 supplied to the pipe to hold the carriage firmly in position 5 provides a drive-in command and so long as it IS maintained without damage to the exterior walls of the pipe and to take l keeps the torch in contact with the work. Sufficient resistance care of heat expansion of the pipe.

is present in theeiectrode material of the torch to provide the The welding torch 1i) and the portion of its drive g j a voltage level necessary to operate the threshold amplifier 278. mechanism 16 which provides for vertical and lateral oscillalt will be recalled also, that the SCR 130 FIG. 6) provides a 20 tion thereof in adirection towards and away from the pipe and short circuit across theterminals 262 and 264 until the weld also in a direction along the axis of the pipe, are mounted on a current is sufficient to start and maintain the are. This proyoke 324 which in turn is mounted on a flange portion 326 of vides an additional safety feature which militates against ima split worm gear which is located in a slot in the carriage 302 a I proper starting'which could cause incomplete melting or sputand rotates around the pipe 300 as the worm gear is driven. A ,tering' with cor sequent damage to the work. As soon as the arc travel motor 328 and its associated worm gear mechanism 330 current is present and the other conditions for are starting and is secured to the carriage 302 by means of bolts 332 which ex- ,imaintenancc of vertical oscillation exist, the lamp L2 is extihtend through holes in the mechanism 330. Thumbscrews 334 I guishe d, thereby preventing the application of the negative hold the worm gear mechanism 330 and its associated motor v voltage from the source at B. A positive voltage is, however, 328 so that the worm in the mechanism 330 engages the worm appliedto the summing point from the MC? 204 (FIG. 7) gear part of the flange 326. Accordingly, the worm may be thereby permittingfthe torch to move away from the work so disconnected from the worm gear so as to facilitate the adjustas to start the arc and maintain it under the control of the verment of the angular position of the pipe 300 with respect to ticaloscillation control systcrn such that the torch will execute the carriage 302. The split gear carriage drive mechanism conu the vertical oscillations in response to the pulsating control sisting of the worm 330, flange worm gear and travel motor current, as was explained in connection with FIGS. ill-I2. 328, may be of a construction similar to that described in US.

v In order to preclude starting until the dissipation of corona Pat. No. 3,389.846, issued June 25, 1968. Reference may be effects. the corona delay circuit 212 includes a capacitor 286 had to that patent for a detailed description and showing of a which is charged through the transistor 288 when the light desuitable carriage drive mechanism. pendent resistor L DR is illuminated. When L DR is extinin order to facilitate the fastening of the yoke to the flange guished, the potential maintained by a pair of zener diodes 40 326, the edge 336 of the yoke 324 is beveled and is inserted 290. which had previously biased the transistor 283 to coninto a complementary beveled slot in the periphery of the ducuon, is'cut off. The capacitor 286 then discharges through flange 326. a pair ofsetscrews 338 are located near the ends of r 'ithe summing network resistor 258 and applies a positive the yoke and hold the yoke in position in the flange 326. In adpotential to the summing point 260 for a time sufiicient to dition, another setsczew 340 extends through the end of the preclude downward movement of the torch toward the work flange 326 and through the yoke's tapered edge 336 to firmly until thecorona effects dissipate; Accordingly, vertical oscillahold the yoke and the drive mechanism 16 mounted thereon tion is inhibited for a short period of time thereby preventing in position for rotation about the pix 300.

possible damage to the work due to corona effects. The principal pa ts of the drive mechanism 16 which are A zener-diode 292 which is connected in series with a remounted on the yoke 324 are the vertical oscillation sistor 294'ar id a lamp L linked to the light dependent resistor mechanism 342, the lateral oscillation mechanism 344 and the L,DR arose the torch and work electrodes 262 and 264 prowire feed mechanism 345. The wire feed mechanism 345 is vide a safety threshold so as to drive or maintain the torch shown in greater detail in FIG. 15. It includes a drive motor t away from the work if the weld voltage exceeds a certain 346 which drives a pair of pinch rollers between which filler i afety threshold. The light dependent resistor L,DR is therewire 343 is pulled from a reel 350 and driven through a tubufore-normally extinguished until the safety threshold is exlar guide tip 352. The end 354 of the tip 352 is flexible. Aceroded. Thereupon, a positive voltage is applied via the cordingly. when the torch 10 is lowered to the pipe 300 during scrftmmg matr x resistor 254 to the summing point which starting of the arc, the torch housing engages the tip and bends drives or maintains Lhe torch in an upward position away from it out of the way so that there is no interference or inadvertent the work. contact of the torch electrode with the wire 348. When the It will therefore be seen that the system of circuits so far torch is raised to normal position. the tip returns to the proper detribedprovides the control signals which automatically position for feeding wire into thejoint being welded. ririve the torch with respect to the work. The mechanisms The entire drive mechanism 16 is fastened to the yoke 324 V which are responsive to the control signals operated by the by means of screws (not shown) which extend laterally motors which are described in connection with the vertical 55 through the yoke. The vertical oscillation mechanism 342 inoscillation and. drive control systems are shown in FlGS. cludcs a drive motor 356 which is fastened to a platform 358 13-20 of the drawings. 7 which is oscillated laterally by the lateral drive mechanism 3 Referring first to FIGS. l3 and 14, the work to be welded is 344. Coupling between the platform 358 and the lateral drive shown as a section of pipe 300 which may have a large diamemechanism 344 is accomplished by means of a pin 360, fixed t er, say of the order of i5 inches. A carriage 302 is clamped to to the platform 358, which extends downwardly from the platthe pipe 300 by means of feet 304 which engage the outer form 358 into engagement with a laterally oscillatory slotted 1 l diameter ofthe pipe at four diametrically opposed points. member 362 which forms part of the lateral oscillating feet 364 are shown in greater detail in FIG. 20. The carmechanism 344. The pin and slotted coupling member 362 are v riage portion on which the feet 304are mounted ismade up of shown in FIGS. 16 and I7 and will be discussed in greater ".two semicircular sections 306 and 308. These sections are detail in connection with these'figures. The Iatera. oscillator mechanism itself includes a drive motor 364 a motion translating mechanism 366 which converts the rotary motion of the motor 364 into controllable amplitude lateral oscillations so as to drive the pin 360 and the platform 3.53.

' The shaft 368 of the motor 356 has a gear at the end thereof which drives a spur gear 370. The spur gearES'Q drives a pinion (not shown) mounted on the same shaft as the gear 370. This pinion drives a rack gear 372 which is connected to a slide 374 which is connected to a bracket 376 by means of a dovetailcoupling 378 which slides in aslot 380 :ne bracket 1 376. Thus,as the motor rotates, the slide 374 will: move up or down, depending upon the sense of motor rotacicla. The posi- 1 tion of the slide 374 maybe adjusted manually by means of a knob 382 which is carried with the slide 374. The end of the knob which extends through the slide 374 has. a gear'384 which is easily rotated by rotating the knob 382. Thi gear engages the rack gear 372; Thus, by turning the knob 382, the

position of the. slide may be adjusted. A worm womr gear drive may be used to drive the slide 374 up and down. A rack gear arrangement, as shown, is however preferab e since its parts are lower cost and reliable. v

A bracket 386 is attached to the slide by mem of a hold down knob 388 which is carried on a bolt extending from the l slide 374 through a slot 390 in the bracket 386. Tcs'torch i is carried on an L-shaped bracket 394 which is also secured in mechanism 345 is also fastened to the bracket 386.

Reference may be had to FlGS. I6 and 17 for a iew of the platform 358 and the translation mechanism 366 62c laterally oscillating the platform 358. The platform 358 a slideably mounted between two sideplatec 396 and 398. The sldeplate 396 is also shown in FlGs. l3 and 14. The back side-:plate 398 is fastened to the yoke 324, as shown in FIG. 14. The sideplates are spaced from each other by means of posts 400.

Bushings an; in the platform are provided so the posts 453 guide the movement of the platform 358 from to side between the sideplates 396 and 398.The platform 35-3 may be pinion 424 meshes with an internal ear 428 having a gea ratio with respect to the pinion 424 o 2: l This internal gear 428'also has an external thread which meshes with a worn 430. The worm 430 may be turned by'rneans of the slottec head 632 thereof so a to rotate the internal gear 428. The

limitsof such rotation are established by means of a pin 438 and a slot436 in the internal gear 428. Another crank 44-0 is fastened to the collar 426 by means of a setscrew 427 so that Thus, when the, motor 364 rotates. the amplitude of lateral oscillation of the pin 442 may be decreased from the maximum amplitude of oscillation thereof. Such maximum am- I plitude of oscillation is obtained when the internal gear is in the position shown in FIG. 19 of the drawings This amplitude may be decreased'to zero by rotating the angle of reciprocation ofcrank 440 to vertical in FIG. l6.

While the gear mechanism 416 is preferred inasmuch as it provides very fine adjustment or" the amplitude of lateral oscillatidn of the torch 10. as well as of the position of the torch,

the brac'ket386 which moves with the slide 374. The wire feed I other mechanisms which afford adjustabl: lateral oscillation may also be provided. For example, a disc having an end face disposed at an angle with respect to its axis may be used as a cam by being spring biased against a follower, such as a ball bearing which is disposed eccentrically with respect to the axis 1 of the cam disc. A housing may be coupled to the cam disc which may be rotated by suitable gearing, such as bevel gears which extend into the housing. By adjusting the eccentricity of the cam disc with respect to its follower, the disc and the housing will oscillate laterally at at amplitudes corresponding to y the set eccentricity.

b ased by means of a spring 404 towards the sidep'late 396.

This spring is designed to counteract the weight of the torch, vertical oscillation motor and other equipment supported by Y the platform 358 should the mechanism be posit-med such that the platform 358 must move up and dorm rather than horizontally as shown in the drawings. 7

The translation mechanism 366 is coupled to the platform 358 by means of a slotted bar 466 which is later-ally oscillated by the mechanism 366. This barhas a bifurcated end 408 through which extends a threaded pin 410 on which the slotted coupling member 362 is located. This n: carries threads 411 engaging the threaded coupling member 362. By

. rotating a knob 415 (see also FIG. I), threaded coupiing 362,

is carried by the threaded pin 410 as it rotates, thereby adjusting the position of the threaded coupling member 361 The pin 360 which depends from the platfom 358 is located in the slot in the coupling member 362. Amdingly, by. rotating the knob, M5, the center of the oscillatory path of I, the platform 358 and therefore of the torch can be set. This cross seam adjustment is especially desirable in the: selects the portion of the joint over which the oscillation tzfces place. As will be described hereinafter, the amplitude of the oscillation is adjustable by means of the translating mechanism 366.

The translating mechanism is shown in FIGS. 18 and 19 as well as in H6. 16. it will be recalled that the slotted bar 406 is coupled to the coupling member 362 so that the iatet'ai oscillation thereof can be translated to the platform S the pin 360 which depends from the platform. The slotted 406 is i f slideably mounted on a pair of pins 414 and is transfixed from left to right as shown in FIG. 16 by a mechanism of gears,

cranks and pins 4'16 (H6. 18). lo this mechanism 416 the shaft 418 of the motor 364 is attached to a crank 421 the arm 422 of which rotates about the axis of the shaft 433 a the shaft 418 is rotated. A pinion 424 having a colic-J 426 is mounted on the arm 422 so that it may rotate i e-i The modifications therein, within the scope of the invention, will undoubtedly suggest themselves to those skilled in the art. Accordingly, the foregoing description should be taken merely as illustrative and not in any limiting sense.

What is claimed is:

l. The method of arc welding which comprises the steps of a. supplying current which pulsates repetitively to provide an are between a torch and the work to be welded,

b. sensing the amplitude of said pulsating current, and

. c. oscillating said torch normally with respect to said work, repetitively varying the distance separating said torch and said work in inverse relationship to said amplitude.

2. The invention as set forth in claim 1 wherein said current supplying step includes the step of selecting the amplitude of the pulses of said pulsating current.

3. A system for arc welding comprising a. a torch b. means for supplying current which pulsates repetitively to said torch for providing an are between the torch and the work to be welded,

c. means for sensing the amplitude of said pulsating current,

and

d. means for oscillating said torch with respect to said work for providing periodic variation in the height of said torch over said work in inverse relationship to said amplitude.

V 4. The invention as set forth in claim 3, wherein said current 

1. The method of arc welding which comprises the steps of a. supplying current which pulsates repetitively to provide an arc between a torch and the work to be welded, b. sensing the amplitude of said pulsating current, and c. oscillating said torch normally with respect to said work, repetitively varying the distance separating said torch and said work in inverse relationship to said amplitude.
 2. The invention as set forth in claim 1 wherein said current supplying step includes the step of selecting the amplitude of the pulses of said pulsating current.
 3. A system for arc welding comprising a. a torch b. means for supplying current which pulsates repetitively to said torch for providing an arc between the torch and the work to be welded, c. means for sensing the amplitude of said pulsating current, and d. means for oscillating said torch with respect to said work for providing periodic variation in the height of said torch over said work in inverse relationship to said amplitude.
 4. The invention as set forth in claim 3, wherein said current supplying means includes means for controlling the amplitude of the pulses of said pulsating current. 